Multi-Carrier Motion Profiles for Collision-Free Linear Transport
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Solution Overview
Problem
In multi-carrier transport systems with linear motors and guide tracks, collisions between transport elements are a significant challenge, especially at high speeds, leading to the need for complex central control systems that often result in system-wide stoppages and production line interruptions.
Innovation Solution
A method that generates and updates movement profiles for transport elements to maintain a minimum distance from the preceding element, using predetermined speed, acceleration, and jerk limits, allowing for predictive control of linear motors to avoid collisions, with decentralized management of distance considerations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If transport elements are moved at high speeds to increase capacity, then productivity is improved, but the risk of collisions increases
Solution Approach 1:
The system performs preliminary actions by calculating and comparing movement profiles before transport elements actually move. The control device determines whether a predetermined minimum distance will be reached by comparing the first movement profile with the second movement profile of the preceding transport element, and updates the movement profile in advance to prevent collisions before they occur.
Solution Approach 2:
The system uses feedback by continuously monitoring and comparing movement profiles of consecutive transport elements. The control device receives information about the second movement profile, compares it with the first movement profile, and uses this feedback to update the first movement profile if necessary to maintain safe distances while optimizing speed.
2Reliability
If a central control system monitors distances cyclically to prevent collisions, then collision avoidance is achieved, but system complexity increases and causes stoppages
Solution Approach 1:
The control system is segmented by assigning independent control capabilities to individual transport elements. Each transport element's control device independently determines and updates its own movement profile by comparing with the preceding element's profile, eliminating the need for a complex centralized monitoring system that would require cyclic distance checks and system-wide stoppages.
Solution Approach 2:
The movement profile serves as an intermediary that carries distance and timing information between transport elements. Instead of direct continuous monitoring and communication between all system components, the movement profiles act as intermediaries that enable decentralized collision avoidance while reducing overall system complexity.
3Reliability
If the movement profile is updated to maintain minimum distance, then collision avoidance is improved, but speed and productivity may be reduced
Solution Approach 1:
The movement profile is dynamic and adaptable rather than fixed. The control device updates the first movement profile based on real-time comparison with the second movement profile, allowing the system to optimize speed while maintaining safe distances. This dynamic adjustment enables the transport elements to travel at maximum speed when safe, and reduces speed only when necessary to maintain the predetermined minimum distance.
Data Source
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AI summary
A method for operating a transport system (10), in particular a multi-carrier system comprising several linear motors (11) arranged in series and having a guide track (13), and several transport elements (15, 17, 19) which can be moved along the guide track (13) by means of the linear motors (11), comprises the following steps: - generating a movement command for a first (15) of the transport elements (15, 17, 19) to move along at least a partial section of the guide track (13), - generating a first motion profile of the first transport element (15) for the movement command based on predetermined motion parameters, - comparing the first motion profile with a second motion profile of a second transport element (17) immediately in front of the first transport element (15) and determining,whether a predetermined minimum distance between the first transport element (15) and the second transport element (17) is not maintained during the execution of the transport order, - updating the first motion profile to maintain the minimum distance if it is determined that the minimum distance is not maintained, and - controlling the linear motors (11) to move the first transport element (15) according to the first motion profile.